Salt indicator in a water conditioning device

ABSTRACT

A regenerating mineral indicator including a detector mechanism to determine whether or not there is a predetermined quantity of mineral resting on a mineral support platform and signal means to warn the operator that either the mineral level is low or bridging has occured. The detector mechanism includes a gas inflated bladder supported on the platform and a conduit having one end in communication with the bladder and the other end in communication with signal means. Various signal means are disclosed which are actuated by the change in pressure in the bladder.

United States Patent 1191 Tischler Aug. 7, 1973 I SALT INDICATOR IN A WATER 3,253,891 5/1966 Hiers 23 272 CONDITIONING DEVICE 3,472,328 10/1969 Holman... 177/208 3,533,095 10/1970 Colllns 340/272 [75] Inventor: Edward J. Tischler, St. Paul, Minn.

I FOREIGN PATENTS OR APPLICATIONS Assgnae Emdyne s70,797 6/1961 United Kingdom 177/208 [22] Filed: Dec. 2, 1970 Primary ExaminerNorman Yudkoff [2]] App! 94467 Assistant Examiner-R. T. Foster Attorney-Charles M. Kaplan and Joel E. Siegel [52] US. Cl 23/272, 73/37, 177/208, 7

I 340/272 [57] ABSTRACT 22 i f A regenerating mineral indicator including a detector 1 77 20's. mechanism to determine whether or not there is a prel l l 3 determined quantity of mineral resting on a mineral support platform and signal means to warn the operator that either the mineral level is low or bridging has oc- [56] 1 References cued cured. The detector mechanism includes a gas inflated UNITED STATES PATENTS bladder supported on the platform and a conduit havl,2l9,723 3/1917 Gracey et a1. 340/240 ing one end in communication with the bladder and the 2,960,328 11/1960 T8116 177/208 other and in communication with ignal mean5 va -i- E y ous signal means are disclosed which are actuated by I'OSIIC I 3,102,175 8/1963 Eichenber'ger.... 340 272 the change m pressure m the b adder 3,169,022 2/1965 Kretsinger 340/272 10 Claims, 8 Drawing Figures SALT INDICATOR IN A WATER CONDITIONING DEVICE BACKGROUND OF THE INVENTION This invention relates to water conditioning apparatus, and more particularly to a device for both determining when the regenerating mineral level is low in a water softener regenerant tank and detecting regenerating mineral bridging in such a tank.

Most water softeners are of the fully automatic type and are regenerated with a regenerating mineral solution, e.g., dissolved sodium chloride (salt). Salt is put into a regenerant or brine tank and water is added to the bottom of the tank. As the water contacts the salt, a portion dissolves to make a brine solution which is then used to regenerate the softener. Periodically, the

' brine tank must be refilled with salt. Since the tank is usuallyopaque and covered, the operator must lift the cover and look inside to determine when the salt level is low.

During the hot, humid summer months, salt bridging frequently occurs in the brine tank. Thisis caused by moisture creeping up into the salt bed and causing the salt particles to adhere together. A salt bridge or cavity forms above the bottom of the tank and prevents water from contacting the salt. Although plenty of salt remains in the tank, none of it is being used to make up brine solution. When the operator checks his brine tank, the only way he can determine whether or not salt bridging has'occurred is by poking in the brine tank witha broom handle or other sharp object.

A device is therefore needed for automatic water softeners which will: l measure the regenerating minimproved regenerating mineral indicator for a water conditioner to indicate when the mineral level in the regenerant tank is low.

Another object is toprovide a regenerating mineral indicator that detects mineral bridging in a water conditioner regenerant tank.

A further object is to provide a regenerating mineral indicator which includes means for externally indicating when the mineral has beenexhausted or when min eral bridging has occurred. 1

A still further object is to provide a regenerating mineral indicator that is inexpensive to manufacture and reliable in operation.

The regenerating mineral indicator mechanism of the present invention comprises a detector mechanism to determine whether or not there is a predetermined quantity of mineral resting on a portion of the mineral supporting platform and a signal unit to warn the operator that either the mineral level is low or bridging has occurred. The detector mechanism is based on a pressurized bladder principle. A rubber bladder is attached to the platform and filled with enough fluid to partially inflate it. Dry regenerating mineral is then added to the tank so asto rest on top of the partially inflated bladder. The weight of the mineral causes the fluid in the bladder to be pressurized. A conduit leading from the bladder is attached to a signal unit, operative'by the fluid pressure in the conduit. By adjusting the amount of fluid in the bladder, the sensitivity of the signal unit can be increased or decreased. Various types of signal units are contemplated by the present invention including the disclosed exemplary electrical, mechanical and A fluid types.

eral level in the brine tank, (2) determine whether or not regeneratingmineral bridging is occurring and (3) relay or transmit this information to the operator.

Prior attempts to solve these problems have included units based on the plumb bob principle. A heavy weight is attached to the end of a string and the weight is placed on top of the dry salt in the brine tank. As the salt is depleted, the weight tightens the string and trips a signal switch to tell the operator when to refill with salt.-There are two problems that exist with the plumb bob device. First, the operator has to remove the weight to replace it on top of the salt after he is through filling the tank. Second, the device only indicates salt level and does not function as a salt bridging'indicator.

Another type of salt indicator is the electrical probe system. An electrical probe is fitted into the bottom of the brine tank and contacts the brine solution. By measuring the conductivity of the liquid the device determines whether or not the brine is at full strength. This type indicator does not give the operator any warning that the salt level is getting low. It merely indicates when the unit is completely out of salt. The operator must add salt immediately or the softener will not function properly on the nextregeneration. This type indicator is addit'onally quite expensive to manufacture.

' A further type of salt indicator is disclosed in US.

Pat. No. 3,253,89l, assigned to the assignee of the present invention. This type indicator operates on the principle of determining the weight of the salt upon the salt platform to indicate the level of salt. However, it does not indicate the presence of salt bridging.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an DESCRIPTION OF THE DRAWINGS The invention, together with its construction and method of operation, along with other objects and advantages thereof, is illustrated more or less diagrammatically in the drawings, in which:

FIG. I is a perspective view of a portion of a'water conditioning system incorporating a salt indicator arrangement embodying features of the present invention, with parts broken away;

FIG. 2 is an elevational view, substantially in cross section, of the salt indicator of the present invention shown in conjunction with an electrical signal means;

FIG. 3 is an elevational view, partially in cross section of an alternative detector means;

FIG. 4 is a front elevational view of an alternative fluid type signal means;

FIG. 5 is a cross sectional view taken along line 5-5 of FIG. 4;

FIG. 6 is a front elevational view of an alternative mechanical type signal means.

FIG. 7 is a cross sectional view taken along line 7-7 of FIG. 6 showing the signal means in the position I which indicates the salt level is not adequate; and;

FIG. 8 is a cross sectional view similar to FIG. 7 showingthe signal means in the position which indicates the salt level is adequate.

DESCRIPTION OF PREFERRED EMBODIMENTS adjacent the treatment tank 12, also withinthe brine tank 11, is a brine well 13. Mounted within the brine tank 11, about three-quarters of the way down, is a horizontally disposed perferated salt platform and seal arrangement of the type disclosed in U. S. Pat. No. 3,502,442, assigned to the same assignee of the present invention. Mounted on the cover of the tank 11 is a conventional system controller (not shown) for causing liquid to flow into and out of tank 11.

Referring to FIG. 2, the salt indicator of the present invention is illustrated generally at 20. Salt indicator includes a detector means and a signal means 30. Detector means 25 determines the quantity of salt resting on a portion of salt platform 15. Signal means warns the operator when the quantity of salt resting on the portion of platform 15 is below a predetermined level.

Detector means 25 includes a bladder 26 made of rubber, or other flexible material, positioned on mounting board 27. The open end of bladder 26 is secured and sealed to one end of fitting 28 in a conventional manner. Fitting 28 has a passageway 29 which communicates with the inside of bladder 26. Attached to the other end of fitting 29 is conduit 31 in communication with bladder 26 via passageway 29. As seen in FIG. 1, detector means 25 is positioned immediately above a central portion of platform 15.

Signal means 30 includes a housing 32 having a cavity 33 therein. Positioned within cavity 33 is a flexible diaphragm 34 dividing cavity 33 into chambers 35 and 36. Insert 37 is attached to diaphragm 34 so as to move therewith, and extends a short distance into chamber 35. Positioned within chamber 35, spaced from and in opposing relationship to insert 37, is micro switch 38 having an actuating member 39 associated therewith. As seen in FIG. 2, switch 38 closes a series circuit 43 including a light indicator means 41 and a source of electrical power 40. Switch 38 is normally closed so that light means 41 will come on when circuit 43 is supplied with power and insert 37 is not in contact with actuating member 39. Conduit 31 is attached to housing 32 at its other end so as to communicate with chamber 36 via passageway 42.

In operation, a quantity of fluid (e.g., air) is injected into bladder 26 which is sufficient to inflate bladder 26 but insufficient to create a pressure in chamber 36 to move diaphragm 34, and insert 37 associated therewith, towards actuating member 39. Micro switch 38 is normally closed so light means 41 comes on when power is supplied through source 40. Salt is then added to brine tank 11, the weight of which compresses the fluid in bladder 26 which increases the pressure in chamber 36 so as to move insert 37 against member 39 and thereby open micro switch 38, thus causing light means 41 to go out. The amount of salt needed to actu-- ate switch 38 can be calibrated by the amount of fluid initially injected into bladder 26, the sensitivity of switch 38, and the clearance between insert 37 and and actuating member 39. When the weight of the salt on bladder 26 is reduced to a pre-determined level the pressure in chamber 36 will likewise be reduced so as to cause insert 37 to move away from member 39 and close switch 38 and thereby turn on light means 41 to indicate more salt is needed.

A reduction of the downward force exerted by the weight of the salt on bladder 26 will result when either the salt supply is sufficiently used up or when salt bridging has occured in the area of bladder 26. Thus the above described mechanism will indicate whenever the quantity of salt positioned immediately above platform 15 and bladder 26 reaches a predetermined level which requires the operator to either add salt or break up any existing salt bridge.

FIG. 3 illustrates an alternative detector means 50 which can be substituted for detector means 25 and positioned on top of platform l5."Detector means 50 includes a housing 51 having an open top portion 53. Closing off the top portion' 53 is a flexible disk 52, of rubber or other flexible material, secured and sealed to the side wall 54 of housing 51 in a conventional manner. Passageway 56, in side wall 54, has one end in communication with the interior of housing 51 and the other end is attached to conduit 31. Detector means 50 operates in a similar manner as detector means 25 and may be substituted therefore.

FIGS. 4 & 5 illustrate an alternative signal means which may be substituted for signal means 30. Signal means 60 includes a housing 61 defining a pair of cavities 62 and 63 therein. Positioned within each cavity 62 and 63 is a cup-shaped flexible diaphragm 64 and 65 respectively, having bottom surfaces 66 and 67 respectively. Diaphragm 64 divides cavity 62 into a lower chamber 78 and an upper chamber 79 and prevents fluid communication therebetween. Likewise, diaphragm 65 divides cavity 63 into a lower chamber 80 and an upper chamber 81 and prevents fluid communi-' cation therebetween. Passageways 68, 69 and 70 define a fluid path which connects upper chamber 79 of cavity 62 with lower chamber 80 of cavity 63. Passageway 69 is defined between a transparent disk member 71 and a portion 72 of housing 61. An indicator sign 73 is secured to portion 72 in a facing relationship to disk 71 and has imprinted thereon a message indicating that salt platform 15 does not have sufficient salt resting thereon, e.g., ADD SALT. Diaphragm 64 and cavity 62 are filled with a fluid 74 to a level immediately below passageway 68. Fluid 74 is the same color as the printing on sign 73 and should be a non-freezing, nonadhering and opaque liquid, e.g. a sodium sulfite solution. An air vent 75 is provided in housing 61 to permit communication between the atmosphere and upper chamber 81 of cavity 63. Passageway 76 extends from lower chamber 78 of cavity 62 through fitting portion 77 of housing 61. One end of conduit 31 is connected to fitting 77.

In operation, a quantity of fluid is injected into bladder 26 which is sufficient to inflate bladder 26 but insufficient to create a pressure in chamber 78 below surface 66 of diaphragm 64 to move surface 66 upwards. Salt is then added to brine tank 11, the weight of which compresses the fluid in bladder 26 which increases the pressure of the fluid in chamber 78 and thereby causes diaphragm 64 to be upwardly displaced. As diaphragm 64 moves upward fluid 74 is displaced from cavity 62 through passageways 68, 69 and 70 into chamber 80 and is forced against surface 67 of diaphragm 65. Diaphragm 65 moves upward to increase the volume of chamber 80 and thereby permits additional fluid 74 to flow thereinto. Since fluid 74 is the same color as the printing on sign 73 the operator will not be able to read the sign through transparent disk 71. When the weight of the salt on bladder 26 is reduced to a pre-determined level the pressure in chamber 78 is likewise reduced so as to cause diaphragm 64 to move downward and fluid 74 to return to chamber 79. As the level of fluid 74 in passageway 69 passes below sign 73 the operator will be able to read the printed message thereon. The weight of the salt needed to retain the level of fluid 74 above sign 73 can be calibrated by the amount of fluid 74 initially put into chamber 79, the size and locations of passageways 68 and 69 and by the amount of fluid initially injected into bladder 26.

FIGS. 6-8 illustrate a second alternative signal means 90 which may be substituted for signal means 30. Signal means 90 includes a housing 91 having a cavity 92 defined therein. A flexible diaphragm 93 divides cavity 92 into a first chamber 94 and a second chamber 95 and prevents fluid communication therebetween. A channel-shaped push arm 96 is secured to diaphragm 93 in a conventional manner and is located intermediate its periphery. Pivotally mounted about a substantially horizontal pin 97, secured to housing 91, is a wedgeshaped indicator member 98. Member 98 is positioned relative to arm 96 such that movement of arm 96 towards and away from member 98 pivots member 98 about pin 97. Secured to member 98 is a sign 99 having a meassage imprinted thereon, e.g., ADD SALT," in a facing relationship to atransparent window 100 in housing 91, as seen in FIG. 7. Conduit 31 is attached to fitting 102 having a passageway 101 therethrough thereby allowing communication between conduit 31 and chamber 94.

In operation, a quantity of fluid is injected into bladder 26 which is sufficient to inflate bladder 26 but insufficient to create a pressure in chamber 94 to move diaphragm 93 and arm 96 towards member 98. When in this position sign 99 is opposite window 100, as seen in FIG. 7. Salt is then added to brine tank 11, the weight of which compresses the fluid in bladder 26 which increases the pressure of the fluid in chamber 94 and thereby causes diaphragm 93 and arm 96 to move towards member 98. Arm 96 contacts member 98 so as to pivot member 98 about pin 97 and assume the position shown in FIG. 8, wherein sign 99 is not opposite window 100. As the weight of the salt on bladder 26 is reduced the pressure chamber 94- is likewise reduced thereby moving diaphragm 93 and arm 96 away from member 98 so as to permit member 98 to pivot about pin 97 due to gravity. When the pressure in chamber 94 is reduced to a predetermined level, member 98 will pivot a sufficient distance until sign 99 is opposite window 100, as seen in FIG. 7. The amount of salt needed to position sign 99 opposite window 100 can be calibrated by adjusting the distance between arm 96 and member 98, changing the volume of chamber 94, the positioning of sign 99 on member 98, and by the amount of fluid initially injected into bladder 26.

It will be understood, that while the forms of the invention herein shown and described constitute preferred embodiments of the invention, it is not intended herein to illustrate all of the equivalent forms or ramifications thereof. It will be understood that the words used are words of description rather than of limitation, and that various changes may be made without departing from the spirit or scope of the invention herein disclosed,and it is 'aimedin the appended claims to cover all such changes as falls within the true spirit and scope of the invention.

What is claimed is: v v

l. A solid regenerating mineral container for awater conditioner of the type in which water flows over said mineral and dissolves same to provide an expendable regenerating solution, thereby consuming said mineral and necessitating replenishment thereof, said container including:

a. a fixed platform for supporting said regenerating mineral;

b. detector means positioned immediately above a predetermined centrally located area of said platform for transmitting a force proportional to the downward force of the portion of said regenerating mineral positioned immediately thereabove; and

c. signal means in communication with said detector means so as to receive said transmitted force and indicate when it is below a predetermined level.

2. The invention of claim 1 wherein said detector means comprises a fluid inflated bladder supported on said platform and conduit means having one end in communication with said bladder and the other end in communication with said signal means such that the weight of said regenerating mineral positioned immediately above said bladder pressurizes the fluid within said bladder and transmits the pressurized fluid through said conduit means to said signal means.-

3. The invention of claim 2 wherein said signal means includes a body portion having a cavity formed therein, said cavity being divided into first and second chambers by a flexible diaphragm, said first chamber being in communication with said conduit means; and switch means in a normally closed position, positioned in said second chamber suc'h thatas said diaphragm moves towards said switch means a predetermined distance due to an increase in pressure in said first chamber said switch means is moved towards its open position.

4. The invention of claim 3 wherein indicator means is associated with said switch means such that when said switch means is in its closed position said indicator means transmits a signal. I

5. The invention of claim 4 wherein said indicator means includes a light means which goes on when said switch means is in its closed position.

6. A solid regenerating mineral container for a water conditioner of the type in which water flows over said mineral and dissolves same to provide an expandable regenerating solution, thereby consuming said mineral and necessitating replenishment there, said container including:

a. a fixed platform for supporting said regenerating mineral;

b. detector means positioned immediately above said platform having a chamber for the confinement of fluid, said chamber having a flexible portion in contact with a central portion of said regenerating mineral; Y

c. conduit means associated with said chamber for transmitting any change of pressure of the fluid confined therein; and

d. signal means associated with said conduit means for indicating when said fluid pressure within said confinement decreases below a predetermined level.

7. The invention of claim 6 wherein said signal means includes:

a. a housing having a cavity therein;

b. a flexible diaphragm dividing said cavity into an upper and lower chamber;

c. a liquid supported above said diaphragm in said upper chamber;

d. said conduit means being in communication with said lower chamber such that as the pressure of the fluid in said lower chamber increases or decreases said diaphragm adjusts the volume of said upper chamber and thereby the level of said liquid.

8. The invention of claim 7 wherein a passageway is provided in fluid communication with said upper chamber, said passageway being defined between an outer transparent sidewall and an inner sidewall having a sign means with a message printed thereof, associated therewith, said liquid being of the same color as said printing on said sign means such that as the liquid level drops in said passageway below said sign means an operator can read said sign means through said outer sidewall.

9. The invention of claim 6 wherein said signal means includes:

a. a housing having a cavity therein;

b. a flexible diaphragm dividing said cavity into first and second chambers; c. arm means associated with said flexible diaphragm and positioned within said second chamber; and d. indicator means pivotal about a substantially horizontal axis positioned within said second chamber opposite said arm means; a e. said conduit means being in communication with said first chamber such that as the pressure of the fluid in said first chamber increases or decreases said diaphragm and arm means associated therewith pivot said indieator means about said substantially horizontal axis. 10. The invention of claim 9 wherein said housing has a window portion opposite a portion of said indicator means and said indicator means has a sign means associated therewith such that as said indicator means pivots about said axis said sign moves in and out of view through said window portion. 

2. The invention of claim 1 wherein said detector means comprises a fluid inflated bladder supported on said platform and conduit means having one end in communication with said bladder and the other end in communication with said signal means such that the weight of said regenerating mineral positioned immediately above said bladder pressurizes the fluid within said bladder and transmits the pressurized fluid through said conduit means to said signal means.
 3. The invention of claim 2 wherein said signal means includes a body portion having a cavity formed therein, said cavity being divided into first and second chambers by a flexible diaphragm, said first chamber being in communication with said conduit means; and switch means in a normally closed position, positioned in said second chamber such that as said diaphragm moves towards said switch means a predetermined distance due to an increasE in pressure in said first chamber said switch means is moved towards its open position.
 4. The invention of claim 3 wherein indicator means is associated with said switch means such that when said switch means is in its closed position said indicator means transmits a signal.
 5. The invention of claim 4 wherein said indicator means includes a light means which goes on when said switch means is in its closed position.
 6. A solid regenerating mineral container for a water conditioner of the type in which water flows over said mineral and dissolves same to provide an expendable regenerating solution, thereby consuming said mineral and necessitating replenishment there, said container including: a. a fixed platform for supporting said regenerating mineral; b. detector means positioned immediately above said platform having a chamber for the confinement of fluid, said chamber having a flexible portion in contact with a central portion of said regenerating mineral; c. conduit means associated with said chamber for transmitting any change of pressure of the fluid confined therein; and d. signal means associated with said conduit means for indicating when said fluid pressure within said confinement decreases below a predetermined level.
 7. The invention of claim 6 wherein said signal means includes: a. a housing having a cavity therein; b. a flexible diaphragm dividing said cavity into an upper and lower chamber; c. a liquid supported above said diaphragm in said upper chamber; d. said conduit means being in communication with said lower chamber such that as the pressure of the fluid in said lower chamber increases or decreases said diaphragm adjusts the volume of said upper chamber and thereby the level of said liquid.
 8. The invention of claim 7 wherein a passageway is provided in fluid communication with said upper chamber, said passageway being defined between an outer transparent sidewall and an inner sidewall having a sign means with a message printed thereof, associated therewith, said liquid being of the same color as said printing on said sign means such that as the liquid level drops in said passageway below said sign means an operator can read said sign means through said outer sidewall.
 9. The invention of claim 6 wherein said signal means includes: a. a housing having a cavity therein; b. a flexible diaphragm dividing said cavity into first and second chambers; c. arm means associated with said flexible diaphragm and positioned within said second chamber; and d. indicator means pivotal about a substantially horizontal axis positioned within said second chamber opposite said arm means; e. said conduit means being in communication with said first chamber such that as the pressure of the fluid in said first chamber increases or decreases said diaphragm and arm means associated therewith pivot said indicator means about said substantially horizontal axis.
 10. The invention of claim 9 wherein said housing has a window portion opposite a portion of said indicator means and said indicator means has a sign means associated therewith such that as said indicator means pivots about said axis said sign moves in and out of view through said window portion. 